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Presented by:
Mark Hasler
MODULA
Tim Archer
Kardex Remstar
Current Trends & Technology In Storage
& Inventory Management
© 2016 MHI® Copyright claimed for audiovisual works and sound recordings of seminar sessions. All rights reserved.
Sponsored by:
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Storage Technology Evolution
Rack Shelving Cabinets Mezzanine
The EVOLUTION of Storage Technologies…
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Storage Technology Evolution If you own, or are thinking about a STATIC storage solution…
STATIC AUTOMATED
Increased Productivity
Space Savings
Improved Accuracy
Ideal Ergonomics
RESULT
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Larger Tray, Carrier & Bin Sizes Available: Vertical Lift Modules:
• Max. Tray Widths of up to 161” Wide
• Max. Tray Depths of up to 50” Deep
Vertical Carousels:
• Max. Carrier Widths of up to 144” Wide
• Max. Carrier Depths of up to 26” Deep
Horizontal Carousels:
• Max. Bin Heights of up to 144” Tall
• Max. Bin Widths of up to 36” Wide
• Max. Bin Depths of up to 24” Deep
Increased Sizes & Capacities
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Increased Sizes & Capacities
Trays Up To 161” Wide
Trays Up To 50” Wide
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Key Benefits:
• Larger trays & carriers have been present for some time, but recently
are gaining widespread acceptance by clients
• More storage provided per tray / carrier
• Increased number of lines picked per tray / carrier
• Fewer units required, when compared to multiple narrower units
• More product in fewer machines under control by less labor
Increased Sizes & Capacities
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Increased Tray & Carrier Weight Capacities Available:
Vertical Lift Modules:
• Max. Tray Load Capacities up to 2,200 Lbs. per Tray
Vertical Carousels:
• Max. Carrier Load Capacities up to 1,650 Lbs. per Carrier
Horizontal Carousels:
• Max. Bin Load Capacities up to 2,200 Lbs. per Bin
Increased Sizes & Capacities
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Increased Sizes & Capacities
Trays Up To 2,200 Lbs.
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Key Benefits:
• VLM units with capacity to 2,200 Lb. trays are readily available
• More storage capacity provided per tray / carrier
• Wider range of products able to be stored, allowing for these
technologies to be applied to more applications
• Ability to store heavy items, previously not able to be stored in VLM
or Vertical Carousel technologies
• More product in fewer machines under control by less labor
Increased Sizes & Capacities
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How Items Are Presented To Users:
Key Points:
• Several different technologies are now available
• Has evolved from a basic, manual presentation to an advanced &
fully automatic presentation
• Faster & more accurate item picking & placing
• Ergonomic benefits for lifting & manipulating heavier items
• Able to accommodate a variety of operator heights
Item Presentation
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• Multiple trays can be delivered to an operator nearly simultaneously
• Ideal for shorter product heights
• When a taller tray is requested, single-tray delivery takes place
Multiple Level Tray Delivery / Presentation:
Benefits:
• Greatly increased throughput
• Decreased picking times
Item Presentation
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Variable Tray Height Presentation For
Ergonomic Picking
Ergonomic, Varied Height Tray Delivery / Presentation:
Benefits:
• Reduced risk of operator injury
• Accommodates a wider range of operators
• Better product visibility
Item Presentation
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Telescopic Tray Extraction
Hinged Tables To Pull Trays Out Onto For Picking
Manual Tray Extraction / Delivery:
Item Presentation
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Benefits:
• Ability to delivery trays out of units automatically
• Provides the ability to have true top picking of items
• Able to be used with overhead cranes & lifting devices
• Provides improved operator ergonomics and safety when compared to manual tray extraction
Fully Automatic or Semi-Automatic Tray Delivery / Presentation:
Item Presentation
Fully Automatic Semi Automatic
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• Ability to transport trays & product to secondary point of use locations
• Multiple carts may be used
Tray Transportation Carts:
Benefits:
• Reduced risk of injury
• Flexible inventory control
Item Presentation
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VLM Tray Partitions & Dividers:
Item Presentation
Benefits:
• Storage areas are able to be easily and efficiently sub-divided into compartments for each SKU
• Easily adjustable and re-configurable
• Provides greater storage density
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Picking Aide Availability & Uses In C/VLM Technology:
Key Points:
• Pick-to-Light technology assists operators with four basic functions:
Picking a specific or active item
Putting an item in an active order or location
Communicating a message such as a quantity, description, etc.
Completing the task and moving to the next task
Advanced Picking Aides
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LED Bar Location Indicators
• Displays the location of the items to pick
Item Location Indication:
Benefits:
• Faster pick times
• Greatly increased accuracy
Advanced Picking Aides
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Text & Location Indication:
LED Bar Text & Location Indicators
• Displays the location of the items to pick left to right & front to back
• Able to display other information useful to users
- Quantity of items to pick or put
- Item description
- Item number
- Lot number and other information
Advanced Picking Aides
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Laser / Light Indicators For Location:
Benefits:
• Increased picking accuracy
• Increased picking speed
• Better operator direction that is
paper & hands free
Advanced Picking Aides
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Benefits:
• Increased Accuracy
• Less Walking = Time Savings
Put-To-Light Batch Order Processing:
Advanced Picking Aides
• Greatly increased throughput
• Able to process dozens of
orders simultaneously
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Ability To Limit Access To A Unit, Tray, or Even Individual Items:
Key Points:
• Large scale versions of industrial vending machines
• Low-volume, high-value, high-security & control
• Adds traceability & accountability
• Avoid intentional theft, as well as over picking “just in case”
• Avoids cross-contamination & misplaced items
Restricted Access Picking
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Ability To Limit Access To A Single Item or Location:
Restricted Access Picking
Limit Access To Only The
Item Required
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Eco-Friendly Options Reduce Energy Consumption & Environmental Impact:
Key Points:
• Manufactured and designed to be as energy-efficient as possible
• VLM’s are available with energy-recovery systems
• Energy-efficient LED lighting is commonly used
• Transition to C/VLM technology saves environmental costs such as
HVAC, lighting, safety and janitorial compared to open-shelving
warehouses
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Advanced Operator Interfaces Human-Machine Interface (HMI) with Advanced Functionalities:
Graphical Color Touch Screen HMI’s:
• Ability to display graphical information of items to pick & the item’s location
• Ability to execute item requests & orders at the HMI
• Some HMI’s feature the ability to store item information on the HMI for stand alone applications
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Advanced Operator Interfaces Controllers Contain Advanced Inventory Management Functionalities:
• No need for a third-party software platform
• Ability to handle even advanced tasks at the operator
station
• Manage inventory even outside of the C/VLM
• Reporting and accounting functions included
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Inventory Management Software Manufacturers Offer Inventory Management Software Packages:
• No need for a third-party software platform
• Ability to handle even advanced tasks at the operator station
• Manage inventory even outside of the C/VLM
• Reporting & accounting functions included
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Key Points:
• Software integration capability – greatly expanded due to open
platform developments
• C/VLM equipment must be smart-enabled
- High graphic content
- Touch screen enabled
- Highly configurable
- Multilingual
- Remote support & upgrades possible
Integration To Clients Greatly Expanded Integration Capabilities:
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Integration To Clients Other Integration Trends & Methodologies:
Key Points:
• Large scale integration – C/VLM equipment performing large
volume, high speed picking in conjunction with other zones and
equipment types
• Integration of forward pick from C/VLM equipment to down line Put
Wall application
• Right equipment for the right product as integrated components
• C/VLM equipment can be integrated to varying degrees, allowing for
everything from simple reporting to complete control
• Integrating with conveyor systems, cranes & robotics through MHI
collaboration
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How Orders Are Processed Flexible Batch Order-Processing, Using C/VLM Technology:
Key Points:
• Traditional batching, but groups of machines with multiple operators working
within a work zone
• The difference with VLM’s is that it is possible to utilize devices within a group
to present picks and then any operator can complete & place (dedicated pick
indicators, put indicators with color, etc.)
• Solves peak capacity problem – also material handling problem & continuous
batching by a non-picking operator. Can also be done with other technologies
such as horizontal & vertical carousels
• Higher throughput, wider range, ability to handle peaks & seasonality
• Flexible labor & staffing – low training threshold
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How Orders Are Processed Flexible Batch Order-Processing, Using C/VLM Technology:
Example Application: 3 pods of VLM units performing flexible batch order processing
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Real-World Application Integrated solution with Vertical Lift Modules,
conveyor, narrow-aisle rack and flow rack.
• Just-In-Time distribution of medical
devices to hospitals
• Support over 500,000 surgeries
per year
• DC turns most orders around in
the same day
• High degree of order accuracy
absolutely necessary
Application:
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Real-World Application Integrated solution with Vertical Lift Modules,
conveyor, narrow-aisle rack and flow rack.
• 3 horizontal carousels grouped to
hold 3,800 SKU’s
• One operator pulls outbound orders
• Software and pick-to-light
technology improved pick accuracy
to 99.9%
• Former system required 5 operators
Results:
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Real-World Application Vertical Lift Modules in Aerospace machining & manufacturing
• Storage of tooling and finished
components
• Client needed to recover floor
space in their facility to add
manufacturing.
• Precision tooling storage for
CAT40 & CAT50 tool holders
Application:
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Real-World Application
• Recovered 85% of previously
occupied floor space
• Enclosed, controlled storage,
with tray holders for tooling
• Software and integration to the
client’s ERP system increased
accuracy and throughput
• Greatly improved productivity
and user ergonomics
Results:
2 Vertical Lift Modules recovered 85% of previously used floor space and integrated to the client’s SAP system
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Real-World Application Vertical Lift Modules used in the Oil & Gas industry
• Parts distribution to a
manufacturing facility
• Plant capacity grew and the
requirement for parts grew also
• Lean 5 Sigma operation
• Need to improve warehouse
operations and improve parts
picking
Application:
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Real-World Application 3 Vertical Lift Modules combined with inventory
management software solved the problem
• 44% productivity improvement
• Labor reduced by 27%
• Recovered 70% of previously
occupied floor space
• Improved ergonomics
Results:
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Real-World Application Vertical Carousel in manufacturing
• Buffer storage for parts in
production
• Ceiling height under 10 feet
• Multiple parts of various heights
• Replaced racks & shelving
Application:
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Real-World Application Vertical Carousels maximize space and provide ergonomic picking
• 301 square feet of storage with a
footprint of only 53 square feet
• All parts are accessed from an
ergonomically correct position
• Carriers in the carousel can be
fitted with intermediate shelves
to accommodate smaller height
totes
Results:
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For More Information:
Mark Hasler – MODULA Email: [email protected]
Website: www.modula.us
Or, visit MODEX 2016 Booth 3247
Tim Archer – Kardex Remstar Email: [email protected]
Website: www. kardexremstar.com
Or, visit MODEX 2016 Booth 4735